Pad and padding

ABSTRACT

A pad, configured to be attached to an item of protective apparel, the pad having a layered construction comprising, in order: a first support layer; a first padded layer; a first low friction layer; a second low friction layer; a second padded layer; and a second support layer connected to the first support layer so as to hold the other layers of the pad together; wherein: the first and second padded layers are configured to slide relative to each other at a sliding interface located between the first and second low friction layers; and the second support layer is configured to stretch to accommodate the sliding.

The present invention relates to a pad and padding for protective apparel.

Protective apparel, including helmets and other headgear, are known for use in various activities. These activities include combat and industrial purposes, such as protective helmets for soldiers and hard-hats or helmets used by builders, mine-workers, or operators of industrial machinery for example. Protective apparel is also common in sporting activities. For example, protective helmets may be used in ice hockey, cycling, motorcycling, motor-car racing, skiing, snow-boarding, skating, skateboarding, equestrian activities, American football, baseball, rugby, soccer, cricket, lacrosse, climbing, golf, airsoft, roller derby and paintballing.

Some protective apparel are rigorously tested. For example, a protective helmet has to be designed so as to satisfy certain legal requirements which relate to, inter alia, the maximum acceleration that may occur in the centre of gravity of the brain at a specified load. Typically, tests are performed, in which a dummy skull equipped with a helmet is subjected to a radial blow towards the head. This has resulted in modem helmets, and other apparel having good energy- absorption capacity in the case of a radial impact.

However, it is also important for protective apparel to effectively protect against an oblique impact, which combines both tangential and radial components. This may be achieved by absorbing and/or dissipating rotation energy and/or redirecting rotational energy into translational energy.

In the case of headgear, such oblique impacts result in both translational acceleration and angular acceleration of the brain. Angular acceleration causes the brain to rotate within the skull, which can result in injuries on bodily elements connecting the brain to the skull and also to the brain itself.

Examples of rotational injuries include Mild Traumatic Brain Injuries (MTBI) such as concussion, and Severe Traumatic Brain Injuries (STBI) such as subdural haematomas (SDH), bleeding as a consequence of blood vessels rapturing, and diffuse axonal injuries (DAI), which can be summarized as nerve fibres being over stretched as a consequence of high shear deformations in the brain tissue.

Depending on the characteristics of the rotational force, such as the duration, amplitude and rate of increase, either concussion, SDH, DAI or a combination of these injuries can be suffered. Generally speaking, SDH occur in the case of accelerations of short duration and great amplitude, while DAI occur in the case of longer and more widespread acceleration loads.

Protective apparel has been developed that reduces the rotational energy transmitted to the wearer by oblique impacts. In some cases (such as the helmets disclosed in WO 2001/045526 and WO 2011/139224) two parts of the apparel may be configured to slide and/or shear relative to each other following an oblique impact, in order to reduce the rotational energy transmitted to the wearer. Connectors may be provided that, whilst connecting the parts of the apparel together, permit sliding and/or shearing of the parts relative to each other under an impact.

When providing protective apparel that comprises sliding and/or shearing parts, the protective function of the apparel is the primary concern. However, this is often at the expense of the comfort of the wearer, the weight and/or size of the apparel, and the cost (e.g. due to increased cost of materials and/or manufacturing).

It is an aim of the present invention to at least partially improve some of the issues described above.

According to an aspect of the invention there is provided a pad, configured to be attached to an item of protective apparel, the pad having a layered construction comprising, in order: a first support layer; a first padded layer; a first low friction layer; a second low friction layer; a second padded layer; and a second support layer connected to the first support layer so as to hold the other layers of the pad together; wherein: the first and second padded layers are configured to slide relative to each other at a sliding interface located between the first and second low friction layers; and the second support layer is configured to stretch to accommodate the sliding.

According to second aspect of the invention there is provided padding for protective apparel, the padding comprising a plurality of distinct pads integrally formed, each pad having a layered construction comprising, in order: a first support layer; a first padded layer; a first low friction layer; a second low friction layer; a second padded layer; and a second support layer connected to the first support layer so as to hold the other layers of the pad together; wherein: the first and second padded layers are configured to slide relative to each other at a sliding interface located between the first and second low friction layers; and the second support layer is configured to stretch to accommodate the sliding.

In the padding of the second aspect, optionally each pad shares a common first support layer. In the padding of the second aspect, optionally each pad shares a common second support layer. Optionally the common first support layer is connected to the common second support layer between each pad.

According to either aspect, optionally, the first and/or second low friction layers are respectively fixedly attached to the first and second padded layers respectively.

Optionally, the first and/or second low friction layer is a plastic. Optionally, the plastic is polycarbonate.

Optionally, the first support layer is formed from a first fabric. Optionally, the first fabric forms part of a hook-and-loop fastening means.

Optionally, the second support layer is formed from a second fabric.

Optionally, the first and/or second padded layer is an energy absorbing layer configured to absorb a radial component of an impact.

Optionally, the first and/or second padded layer is a comfort padded layer.

According to a third aspect of the invention there is provided, protective apparel comprising the pad or padding of any preceding aspect.

Optionally, the pad or padding forms an interface layer of the apparel configured to interface with a wearer.

Optionally, the pad or padding forms an outer layer of the apparel configured to directly receive an impact.

Optionally, the apparel is substantially formed from the padding, such that one of the first support layer and the second support layer forms an interface layer of the apparel configured to interface with a wearer and the other of the first support layer and the second support layer forms an outer layer of the apparel configured to directly receive an impact.

Optionally, the apparel is headgear.

According to a fourth aspect of the invention helmet comprising: an outer shell; an energy absorbing layer arranged radially inward of the outer shell; and the pad or padding of any previous aspect provided on a radially inward facing surface of the energy absorbing layer.

According to a fifth aspect there is provided a helmet comprising: an outer shell; a head mount configured to mount the helmet on a wearer’s head, suspended radially inward of the outer shell with a gap there between; and the pad or padding of any previous aspect provided on radially inward facing surface of the head mount.

According to a sixth aspect there is provided soft headgear for contact field sports, such as rugby and/or soccer, comprising: an inner layer configured to accommodate a wearer’s head; an outer layer covering at least a part of the inner layer; wherein the headgear is substantially formed from the padding of the second aspect, such that one of the first support layer and the second support layer forms the inner layer of the headgear and the other of the first support layer and the second support layer forms the outer layer of the headgear.

The invention is described in detail below, with reference to the accompanying figures, in which:

FIG. 1 depicts a cross-section through an example pad;

FIG. 2 depicts the pad of FIG. 1 during an oblique impact;

FIG. 3 is a perspective view of the pad of FIG. 1 ;

FIG. 4 shows an example of padding;

FIG. 5 depicts an example method of manufacturing padding;

FIG. 6 shows a pad attached to an item of apparel;

FIG. 7 depicts a first example helmet;

FIG. 8 depicts a cross-section through a second example helmet;

FIG. 9 is a diagram showing the functioning principle of the helmet of FIG. 8 ;

FIGS. 10A, 10B & 10C show variations of the structure of the helmet of FIG. 8 ;

FIGS. 11 and 12 schematically depict a third example helmet;

FIG. 13 depicts a fourth example helmet;

FIG. 14 depicts a further example of headgear.

FIGS. 1 to 3 show different views of a first example pad 100 in accordance with the invention. FIG. 1 is a cross-sectional view showing the layered construction of the pad 100. The pad 100 comprises a first support layer 101, as a first layer. The first support layer 101 forms a first outer surface of the pad 100. The pad 100 further comprises a second support layer 102, as a final layer. The second support layer 102 forms a second outer surface of the pad 100. The second support layer 102 is connected to the first support layer 101, so as to hold the other layers of the pad 100 together. For example, the first and second layers 101, 102 may form a pouch containing the other layers.

Between the first and second support layers 101, 102 are provided first and second padded layers 103, 104. The padded layers 103, 104 may be formed from a gel material or a foam material for example. The properties of the gel material or foam material may be selected for a specific purpose, such as for energy absorbing or comfort. For energy absorbing, a relatively high density material might be chosen such as expanded polystyrene (EPS), expanded polypropylene (EPP), expanded polyurethane (EPU), or expanded ethylene-vinyl acetate (EVA). For comfort, a relatively low density material might be chosen such as latex, EVA and/or PVC foam, for example.

Energy absorbing materials are those designed to absorb the energy of an impact. Other components may absorb that energy to a limited extent, but that is not their primary purpose and their contribution to the energy absorption is minimal compared to the energy absorption of the energy absorbing material. Indeed, although comfort padding may be made of ‘compressible’ materials, and as such considered as ‘energy absorbing’ in other contexts, it is well recognised in the field of protective apparel that compressible materials are not necessarily ‘energy absorbing’ in the sense of absorbing a meaningful amount of energy during an impact, for the purposes of reducing the harm to the wearer.

The first and second padded layers 103, 104 in the pad 100 may be any combination of material types. For example, the may both be energy absorbing, both be comfort padding or one may be energy absorbing and the other comfort padding. For applications where the pad 100 may come into contact with a wearer, i.e. at an interface between the apparel and the wearer, at least one comfort padding layer may be preferable. More preferably this may be the padded layer closest to the wearer.

The padded layers 103, 104 are preferably relatively thin in the thickness dimension, compared to width or length. Accordingly, they may be sheet-like. Indeed they may be formed from a larger sheet of material. The shape of the padded layers 103, 104 is not particularly important. However, for symmetry, circular disks may be preferred. Squares or rectangles are also suitable, as are other shapes. Preferably, the padded layers 103, 104 are the same size and shape.

Between the first and second padded layers 103, 104 are provided first and second low friction layers 105, 106. The low friction layers 103, 104 may be fixed to or integrated with respective opposing surfaces of the first and second padded layers 103, 104. Alternatively, the low friction layers 103, 104 may be loose within the pad 100. Accordingly, a low friction interface is provided between the first and second low friction layers 105, 106 and, by extension, between the first and second padded layers 103, 104. Therefore, the first and second padded layers 103, 104 are able to slide relative each other. The sliding occurs in a plane substantially parallel to the padded layers 103, 104.

The low friction layers 103, 104 may be formed from a plastic, such as polycarbonate (PC), or a composite material. In some arrangements, it may be desirable to configure the low friction layers 105, 106 such that the coefficient of friction at the sliding interface is between 0.001 and 0.3 and/or below 0.15.

The sliding may in a relative movement between first and second padding layers 103, 104 in a range of between 1 mm and 100 mm, optionally greater than 5 mm, 10 mm, or 15 mm, optionally less than 15 mm, 20 mm or 30 mm.

The above described sliding between the first and second padded layers 103, 104 is further facilitated by the second support surface 102, which is configured to stretch to accommodate the sliding. Accordingly, the second support 102 surface may be formed from a stretchable material, such as a stretchable fabric, like Lycra™.

The first support layer 101 may also be formed from a stretchable material, however, this is not necessary. In some embodiments, the first support layer 101 may be formed from a fabric material that forms part of a hook-and-loop (Velcro™) fastening means. For example, the first support layer 101 may be formed from brushed nylon (soft Velcro™). This arrangement means that the first support layer 101 and the pad 100 as a whole can easily be attached to an item of protective apparel. In alternative embodiments, alternative fastening means may be used, that are attached to the first support layer, such as poppers, magnets, glue or tape.

In some embodiments, the first and second support layers 101, 102 may, for example, be formed from a textile, a cloth and/or a fabric. These may be constructed from synthetic yarns, such as Polyester (PES), Polyamide (PA, e.g. PA6) and/or Elastane, natural yarns, such as cotton and/or wool, or a combination of both. However, other materials may also be used, including felts and directly-formed flexible sheet materials including, for example, leather and/or artificial leather. Preferably, the inner and outer layers are made from soft, thin materials so as not to cause injury to wearers.

It should be appreciated that the first and second support layers 101, 102 may be formed from different materials and/or different types of material. The layer of material to be provided on the inside of the headgear may be selected for one particular quality, such as comfort for the wearer, while a second material may be selected for the other layer, for example for wear resistance. Alternatively, both layers may be formed from the same material.

The first and second support layers 101, 102 may be connected to each other by heat welding, stitching or other means.

Although not shown in the figures, further padded layers and corresponding low friction layers may be provided. For example rather than two padded layers with one sliding interface between them, there may be N padded layers, with N-1 sliding interfaces (where N is an integer greater than two). Three padded layers may be particularly advantageous for some applications. For example, with three padded layers, an energy absorbing padded layer can be arranged between two comfort padding padded layers.

FIG. 2 shows the sliding movement with the pad 100 resulting from an oblique impact. As shown, the first and second padded layers 103, 104 become displaced from each other as they slide and deform the second support layer 102. As shown, the first support layer 101 may remain substantially undeformed.

FIG. 3 shows an external view of the first example pad 100. From this perspective it can be seen that the second support layer 102, entirely covers the internal layers of the pad, namely the padded layers 103, 104 and low friction layers 105, 106. However, in alternative embodiments, this may not be the case. For example, partial coverage may be provided by gaps or perforations within the second support layer 102. The second support layer 102 may be formed from meshed material, for example

FIG. 4 shows an example of padding 200 comprising a plurality of distinct pads integrally formed together. The individual pads 100, are each the same as the pad 100 described above. However, the pads are formed together in a single structure, i.e. padding 200. Padding 200 may be formed in sheets having any desired shape and with any desired pattern of pads 100.

The distinct pads 100 forming the padding 200 may vary in size and/or shape from one another, and/or in the padding materials and/or low friction materials used. However, preferably the distinct pads 100 forming the padding 200 share a common first support layer 101 and/or a common second support layer 102. Preferably still, the common support layers are connected to each other between the pads 100, e.g. at least around the perimeter of the pads and possibly also in the space between.

FIG. 5 shows a possible method of manufacturing the padding 200 in which the first support layer 101 is laid out, the first and second padded layers 103, 104 and first and second low friction layers 105, 106 arranged on the first support layer, the second support layer 102 laid out on top of those, and high frequency welds formed between the pads. The reverse order may be used, of course.

FIG. 6 shows a first example of the pads 100 being used within an item of protective apparel 300. However, it should be understood that the padding 200 may be used in the same way. As shown, the pad 100 forms an interface layer of the apparel 300 configured to interface with a wearer. For example, the pad 100 may be attached to, or replace, existing structures that would otherwise come into contact with the wearer, such as an energy absorbing layer or head mount. The attachment may be made by complementary fastening means 301 to any fastening means provided to the pad 100 described above, in this case a hook and loop fastening means 301.

Below are described a number of examples of protective helmets to which the pads 100 or padding 200 may be applied. Multiple pads 100 may be used and/or multiple sections of padding 200. The proportions of the thicknesses of the various layers depicted in the figures have been exaggerated in the drawings for the sake of clarity and can of course be adapted according to need and requirements.

FIG. 7 depicts a first helmet 1 having a structure typical of many protective helmets, such as cycling helmets. The helmet 1 comprises an energy absorbing layer 3. The energy absorbing layer 3 is designed for absorbing the energy of an impact. The energy absorbing layer 3 is relatively thick (e.g. compared to other layers of the helmet). As such, it is effective at damping or absorbing impacts against the head. It can advantageously be made of foam material like expanded polystyrene (EPS), expanded polypropylene (EPP), expanded polyurethane (EPU), vinyl nitrile foam; or other materials forming a honeycomblike structure, for example; or strain rate sensitive foams such as marketed under the brand-names Poron™ and D3O™. The construction can be varied in many different ways.

The helmet 1 shown in FIG. 7 further comprises an outer shell 2. However, this outer shell 2 is optional. The outer shell 2 is provided radially outward of the energy absorbing layer 3, so as to partially or completely cover the energy absorbing layer. Accordingly, the energy absorbing layer 3 is sometimes referred to as a “liner”.

The outer shell 2 is preferably relatively thin (e.g. compared to the energy absorbing layer 3) and strong so as to withstand impact of various types. The outer shell 2 could be made of a polymer material such as polycarbonate (PC), polyvinylchloride (PVC) or acrylonitrile butadiene styrene (ABS) for example. Advantageously, the polymer material can be fibre-reinforced, using materials such as glass-fibre, Aramid, Twaron, carbon-fibre or Kevlar.

Although not shown, the helmet 1 may further comprise a head mount located radially inward of the energy absorbing layer 3. Pads 100 or padding 200 may be attached to an inward facing surface of the energy absorbing layer 3 or head mount that would otherwise contact the wearer’s head. Providing the above described pads 100 or padding 200 to this type of helmet improves the protection provided by the helmet against oblique impacts without compromising comfort. Further the pads 100 or padding 200 may be retrofitted to existing helmets.

FIG. 8 depicts a second example helmet, similarly constructed with an outer shell 2 and, arranged inside the outer shell 2, an energy absorbing layer 3. However, unlike the helmet shown in Fig., the second example helmet is configured such that the outer shell 2 and the energy absorbing layer 3 slide relative to each other in response to an oblique impact to the helmet at a sliding interface provided between the outer shell 2 and the energy absorbing layer 3.

Arranged between the outer shell 2 and the energy absorbing layer 3, at the sliding interface is a sliding layer 4 (also called a sliding facilitator or low friction layer), which may enable displacement between the outer shell 2 and the inner shell 3. In particular, the sliding layer 4 may be configured such that sliding occurs between the two parts during an impact. For example, the sliding layer 4 may be configured to enable sliding under forces associated with an impact on the helmet 1 that is expected to be survivable for the wearer of the helmet 1.

The helmet 1 shown in FIG. 8 may comprise one or more connectors 5 which interconnect the outer shell 2 and the energy absorbing layer 3, while permitting relative movement between the two parts.

The sliding layer 4 can be provided in many different ways. For example oil, Teflon, microspheres, air, rubber, polycarbonate (PC), a fabric material such as felt, etc. Such a layer may have a thickness of roughly 0.1-5 mm, but other thicknesses can also be used, depending on the material selected and the performance desired. The number of sliding layers and their positioning can also be varied, and an example of this is discussed below (with reference to FIG. 10 b ).

FIG. 9 shows the functioning principle of protective helmet 1, in which the helmet 1 and a skull 10 of a wearer are assumed to be semi-cylindrical, with the skull 10 being mounted on a longitudinal axis 11. Torsional force and torque are transmitted to the skull 10 when the helmet 1 is subjected to an oblique impact K. The impact force K gives rise to both a tangential force K_(T) and a radial force K_(R) against the protective helmet 1. In this particular context, only the helmet-rotating tangential force K_(T) and its effect are of interest.

As can be seen, the force K gives rise to a displacement 12 of the outer shell 2 relative to the energy absorbing layer 3, the connecting members 5 being deformed. Significant reductions in the torsional force transmitted to the skull 10 can be obtained with such an arrangement. A typical reduction may be roughly 25% but reductions as high as 90% may be possible in some instances. This is a result of the sliding motion between the energy absorbing layer 3 and the outer shell 2.

Sliding motion can also occur in the circumferential direction of the protective helmet 1, although this is not depicted. This can be as a consequence of circumferential angular rotation between the outer shell 2 and the energy absorbing layer 3 (i.e. during an impact the outer shell 2 can be rotated by a circumferential angle relative to energy absorbing layer 3).

A few possible variants of the helmet shown in FIG. 8 are shown in FIGS. 10 . In FIG. 10 a , the energy absorbing layer 3 is constructed from a relatively thin outer layer 3″ and a relatively thick inner layer 3′. The outer layer 3″ is preferably harder than the inner layer 3′, to help facilitate the sliding with respect to outer shell 2. In FIG. 10 b , the inner shell 3 is constructed in the same manner as in FIG. 10 a . In this case, however, there are two sliding layers 4, between which there is an intermediate shell 6. The two sliding layers 4 can, if so desired, be embodied differently and/or made of different materials. One possibility, for example, is to have lower friction in the outer sliding layer than in the inner. In FIG. 10 c , the energy absorbing layer 3 is embodied differently from previously. In this case, the energy absorbing layer 3 is provided as an outer layer 3′ and an inner layer 3″, with the sliding layer 4 provided between the outer layer 3′ and an inner layer 3″ forming the energy absorbing layer 3. The inner and outer layers of the energy absorbing layer 3 may be formed from the same material or different materials.

Pads 100 or padding 200 may be attached to an inward facing surface of the energy absorbing layer 3 or head mount, that would otherwise contact the wearer’s head. Providing the above described pads 100 or padding 200 to this type of helmet further improves the protection provided by the helmet against oblique impacts without compromising comfort. Further, the sliding function can be shared between different structures of the helmet, thus lowering the engineering burden on each structure or providing redundancy. The pads 100 or padding 200 may be retrofitted to existing helmets.

FIG. 11 depicts a third example helmet 1 similarly constructed with an outer shell 2 and, arranged inside the outer shell 2, an energy absorbing layer 3. In addition, the helmet 1 comprises a head mount 13 provided radially inward of the energy absorbing layer 3. The third example helmet is configured such that the energy absorbing layer 3 and the head mount 13 slide relative to each other in response to an oblique impact to the helmet, at a sliding interface provided between the energy absorbing layer 3 and the head mount 13.

The head mount 13 may be provided in any form that may conform to the head of a wearer and mount the helmet to the wearer’s head. In some configurations, it may assist in securing the helmet 1 to the wearer’s head but this is not essential. In some arrangements, the head mount 20 may include a head band that at least partially surrounds the wearer’s head. Alternatively or additionally, the head mount 20 may include one or more straps that extend across the top of the wearer’s head. Alternatively or additionally, the head mount 20 may include a cap or shell that encapsulates an upper portion of the wearer’s head. The head mounts mentioned earlier in the context of other helmets may be the same as described here.

A sliding facilitator 4 is provided radially inwards of the energy absorbing layer 3, at the sliding interface. The sliding facilitator 4 is provided to assist sliding of the energy absorbing layer 3 in relation to an head mount 13, in the same manner as discussed above in relation to the second example helmet. The sliding facilitator 4 may be a material having a low coefficient of friction, or may be coated with such a material.

As such, in the FIG. 11 helmet, the sliding facilitator 8 may be provided on or integrated with the innermost side of the energy absorbing layer 3, facing the head mount 13. However, it is equally conceivable that the sliding facilitator 4 may be provided on or integrated with the outer surface of the head mount 13, for the same purpose of providing slidability between the energy absorbing layer 3 and the head mount 13. That is, in particular arrangements, the head mount 13 itself can be adapted to act as a sliding facilitator 4 and may comprise a low friction material.

In other words, the sliding facilitator 4 is provided radially inwards of the energy absorbing layer 3. The sliding facilitator can also be provided radially outwards of the head mount 13.

Multiple sliding facilitators 4 may be provided, e.g. as patches of low friction material. The low friction material may be a waxy polymer, such as PTFE, ABS, PVC, PC, Nylon, PFA, EEP, PE and UHMWPE, or a powder material which could be infused with a lubricant. The low friction material could be a fabric material. As discussed, this low friction material could be applied to either one, or both of the sliding facilitator and the energy absorbing layer.

The head mount 13 can be fixed to the energy absorbing layer 3 and/ or the outer shell 2 by means of connectors 5, such as the four connectors 5 a, 5 b, 5 c and 5 d in FIG. 5 .

FIG. 12 shows an arrangement of a helmet similar to the helmet in FIG. 11 , when placed on a wearer’s head. A frontal oblique impact I creating a rotational force to the helmet is shown in FIG. 12 . The oblique impact I causes the energy absorbing layer 3 to slide in relation to the head mount 13. The head mount 13 is fixed to the energy absorbing layer 3 by means of the fixing members 5 a, 5 b. The fixing members 5 may absorb the rotational forces by deforming elastically or semi-elastically. In other arrangements, the deformation may be plastic, even resulting in the severing of one or more of the fixing members 5. In the case of plastic deformation, at least the fixing members 5 will need to be replaced after an impact. In some case a combination of plastic and elastic deformation in the fixing members 5 may occur, i.e. some fixing members 5 rupture, absorbing energy plastically, whilst other fixing members deform and absorb forces elastically.

Pads 100 or padding 200 may be attached to an inward facing surface of the head mount 13 that would otherwise contact the wearer’s head. Providing the above described pads 100 or padding 200 to this type of helmet further improves the protection provided by the helmet against oblique impacts without compromising comfort. Further, the sliding function can be shared between different structures of the helmet, thus lowering the engineering burden on each structure or providing redundancy. The pads 100 or padding 200 may be retrofitted to existing helmets.

FIG. 13 schematically depicts a fourth example helmet 1. As shown in FIG. 1 a head mount 20 is suspended within an outer shell 2 such that an air gap 21 is provided between the outer shell 2 and the head mount 20. Helmets of this type are commonly used for industrial purposes, such as by builders, mine-workers or operators of industrial machinery. However, helmets based on such an arrangement may be used for other purposes. The outer shell 2 and head mount 20 may be the same as described previously in relation to other example helmets.

In a helmet such as that depicted in FIG. 13 , the provision of an air gap 21 between the inner surface of the outer shell 2 and the head mount 20 is intended to ensure that loading caused by an impact on the outer shell 2 is spread across a wearer’s head. In particular, the load is not localised on a point on the wearer’s head adjacent the point of impact on the helmet 1. Instead, the load is spread across the outer shell 2 and, subsequently, spread across the head mount 20 and therefore spread across the wearer’s skull.

The size of the air gap 21 between the outer shell 2 and the head mount 20 may be chosen to ensure that, under an impact on the helmet that the helmet is designed to withstand, the head mount 20 does not come into contact with the outer shell 2, namely the air gap 21 is not entirely eliminated. In an arrangement, the helmet 1 may be configured such that, in the absence of an impact on the helmet, the separation between the outer shell 2 and the head mount 20 at a location corresponding to the top of the head of a wearer is at least 10 mm, optionally at least 15 mm, optionally at least 20 mm, optionally at least 30 mm, optionally at least 40 mm. The magnitude of the impact that the helmet 1 is designed to withstand, and therefore the size of the air gap 21, may depend upon the intended use of the helmet 1. It should be understood that, depending on the intended use of the helmet the size of the air gap 21 may be different at different locations. For example, the air gap 21 may be smaller at the front, back or side of the helmet than it is at the location corresponding to the top of the head of the wearer.

As shown in FIG. 13 , the head mount 20 includes a plurality of connectors 25 that are provided between the outer shell 2 and the head mount 20 and are configured to suspend the head mount 20 within the outer shell 2 in order to provide the air gap 21 between the outer shell 2 and the head mount 20. It should be appreciated that, where the head mount 20 is formed from a plurality of sections, such as a head band, straps that extend across the top of the wearer’s head and/or a cap or shell, it may be sufficient for one of those components to be attached to the outer shell by the connectors. Alternatively, different elements of the head mount 20 may have respective connectors. In that case, the connectors 25 for different parts of the head mount 20 may be the same or may be different from each other.

In an arrangement, the connectors 25 may be configured to be relatively elastic, namely to have a lower modulus of elasticity than the outer shell 2 and/or the head mount 20. For the avoidance of doubt, references to the modulus of elasticity of a component refers to the ratio of the force exerted on the component to the extension induced by the force within a given range of extension. It should be appreciated that, for a component formed from multiple elements, this may differ from the modulus of elasticity for the bulk material from which it is formed.

By connecting the head mount 20 to the outer shell 2 using relatively elastic connectors 25, the outer shell 2 may rotate relative to the head mount 20 in response to an impact, providing corresponding benefits in respect of managing impact energies that were discussed above. Depending on the intended use of the helmet and the configuration of the helmet and the connectors 25, the outer shell 2 may be able to rotate relative to the head mount 20 about different axes, such as an axis extending generally from the front to the back of the head of the wearer, an axis extending generally from side to side of the head of the wearer and an axis extending generally parallel to the spine of the wearer. Appropriate design of the helmet and the connectors 25 enables control of rotation of the outer shell 2 relative to the head mount 20 about the different axes in response to different impacts.

Pads 100 or padding 200 may be attached to an inward facing surface of the head mount 13 that would otherwise contact the wearer’s head. Providing the above described pads 100 or padding 200 to this type of helmet further improves the protection provided by the helmet against oblique impacts without compromising comfort. Further, the sliding function can be shared between different structures of the helmet, thus lowering the engineering burden on each structure or providing redundancy. The pads 100 or padding 200 may be retrofitted to existing helmets.

In contrast to the above described examples, the pads 100 or padding 200 may form an outer layer (i.e. with respect to the wearer) of the apparel configured to directly receive an impact. For example, the pads 100 or padding 200 may be attached to the outer surface of the outer shell, or energy absorbing layer, of any of the example helmets described above. In a specific example, a single layer of padding 200 (appropriately shaped) may be configured to cover the entire outer shell 2.

In another specific example shown in FIG. 14 , the apparel itself might be substantially formed from the padding 200. For example, the apparel may be configured such that one of the first support layer and the second support layer forms an interface layer of the apparel configured to interface with a wearer and the other of the first support layer and the second support layer forms an outer layer of the apparel configured to directly receive an impact.

The apparel shown in FIG. 14 is an example of soft headgear 40 of the type suitable for rugby or soccer. The profile of the headgear 40 shows that this example headgear is provided in the form of a cap configured to cover the top of the wearer’s head. The sides, back and/or forehead may also be covered by the cap, as shown. As shown, the headgear may comprise apertures 41 located around the ears (e.g. to aid hearing), a chin strap 42 and apertures 43 for ventilation.

The headgear 40 is substantially formed from padding 200 such that the first support layer 101 forms an inner layer configured to accommodate a wearer’s head. Accordingly, the inner layer defines a cavity within which a head can be inserted. The second support layer 102 forms an outer layer of the headgear 40. The padded layers 103, 103, and low friction layers 104, 105 are configured to absorb and/or redirect energy of an impact between the headgear and an object.

The pads 100 of the padding 200 may be configured to cover the top and/or sides of the wearer’s head. Preferably, the padded layers 103, 104 are made from soft, thin materials so as not to cause injury to players.

In the above example headgear 40, it may be preferable that the padding layers facing towards the wearer has the same texture, hardness and/or density as the padding facing away from the wearer. This may ensure that the forces experiences by the wearer and an opponent are similar.

In the above example headgear 40, it may be preferable that the padded layer has a maximum uncompressed thickness of no more than 1 cm, and/or has a maximum density of no more than 60 kilograms per cubic meter, or optionally no more than 45 kilograms per cubic meter.

Alternatively, the headgear 40 may be provided in the form of a headband configured to encircle the wearer’s head. The headband may be configured to at least cover the forehead of the wearer. The ears may also be covered.

Variations of the above described embodiments are possible in light of the above teachings. It is to be understood that the invention may be practiced otherwise and specifically described herein without departing from the spirit and scope of the invention. 

1. A pad, configured to be attached to an item of protective apparel, the pad having a layered construction comprising, in order: a first support layer; a first padded layer; a first low friction layer; a second low friction layer; a second padded layer; and a second support layer connected to the first support layer so as to hold the other layers of the pad together; wherein: the first and second padded layers are configured to slide relative to each other at a sliding interface located between the first and second low friction layers; and the second support layer is configured to stretch to accommodate the sliding.
 2. Padding for protective apparel, the padding comprising a plurality of distinct pads integrally formed, each pad having a layered construction comprising, in order: a first support layer; a first padded layer; a first low friction layer; a second low friction layer; a second padded layer; and a second support layer connected to the first support layer so as to hold the other layers of the pad together; wherein: the first and second padded layers are configured to slide relative to each other at a sliding interface located between the first and second low friction layers; and the second support layer is configured to stretch to accommodate the sliding.
 3. The padding of claim 2, wherein each pad shares a common first support layer.
 4. The padding of claim 2 or 3, wherein each pad shares a common second support layer.
 5. The padding of claim 3 and claim 4, wherein the common first support layer is connected to the common second support layer between each pad.
 6. The pad or padding of any preceding claim, wherein the first and/or second low friction layers are respectively fixedly attached to the first and second padded layers respectively.
 7. The pad or padding of any preceding claim, wherein the first and/or second low friction layer is a plastic.
 8. The pad or padding of claim 7, wherein the plastic is polycarbonate.
 9. The pad or padding of any preceding claim, wherein the first support layer is formed from a first fabric.
 10. The pad or padding of claim 9, wherein the first fabric forms part of a hook-and-loop fastening means.
 11. The pad or padding of any preceding claim, wherein the second support layer is formed from a second fabric.
 12. The pad or padding of any preceding claim, wherein the first and/or second padded layer is an energy absorbing layer configured to absorb a radial component of an impact.
 13. The pad or padding of any preceding claim, wherein the first and/or second padded layer is a comfort padded layer.
 14. Protective apparel comprising the pad or padding of any preceding claim.
 15. The protective apparel of claim 14, wherein the pad or padding forms an interface layer of the apparel configured to interface with a wearer.
 16. The protective apparel of claim 15, wherein the pad or padding forms an outer layer of the apparel configured to directly receive an impact.
 17. The protective apparel of claim 14, wherein the apparel is substantially formed from the padding, such that one of the first support layer and the second support layer forms an interface layer of the apparel configured to interface with a wearer and the other of the first support layer and the second support layer forms an outer layer of the apparel configured to directly receive an impact.
 18. The protective apparel of any preceding claim, wherein the apparel is headgear.
 19. A helmet comprising: an outer shell; an energy absorbing layer arranged radially inward of the outer shell; and the pad or padding of any one of claims 1 to 13 provided on a radially inward facing surface of the energy absorbing layer.
 20. A helmet comprising: an outer shell; a head mount configured to mount the helmet on a wearer’s head, suspended radially inward of the outer shell with a gap there between; and the pad or padding of any one of claims 1 to 13 provided on radially inward facing surface of the head mount.
 21. Soft headgear for contact field sports, such as rugby and/or soccer, comprising: an inner layer configured to accommodate a wearer’s head; an outer layer covering at least a part of the inner layer; wherein the headgear is substantially formed from the padding of any one of claims 2 to 13, such that one of the first support layer and the second support layer forms the inner layer of the headgear and the other of the first support layer and the second support layer forms the outer layer of the headgear. 